Blue Mule - 1986 110 3dr Build - Page 17 - Defender Source
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  #321  
Old October 20th, 2015, 05:52 PM
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Don Bunnell
'86 110 3dr ST
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Quote:
Originally Posted by LostChord View Post
Looks amazing Don - love following your build!
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Originally Posted by sonoronos View Post
Looks wicked.
Thanks boys!
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  #322  
Old October 20th, 2015, 05:59 PM
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Don Bunnell
'86 110 3dr ST
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Added M4 nutserts where the holes were for the rear lights. This way I can run stainless M4 screws and not worry about the aluminum corroding. Plus I will less likely cut my hand when messing with wiring in the back well.

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  #323  
Old October 20th, 2015, 06:04 PM
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Don Bunnell
'86 110 3dr ST
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Lights all in - I still need to finish some wiring but waiting on a package with the connectors I need.

I am running twin reverse lights using clear UK/ROW Wilpac LED lights.

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  #324  
Old October 20th, 2015, 06:06 PM
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Don Bunnell
'86 110 3dr ST
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Spare tire is back on.

I need to make some angle iron back plates for the hinges and the latch to make things nice and solid.

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  #325  
Old October 21st, 2015, 11:07 AM
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Dan Pollock
1983 Defender 3 Door
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Hey Don, three questions for you. 1) did you shop a full heigh door down to make that door? 2) how well does the door work with the full weight of the wheel on just the two hinges and 3) is that a SD roll cage? did you buy new?
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  #326  
Old October 21st, 2015, 12:23 PM
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Don Bunnell
'86 110 3dr ST
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Quote:
Originally Posted by DPdotCOM View Post
Hey Don, three questions for you. 1) did you shop a full heigh door down to make that door? 2) how well does the door work with the full weight of the wheel on just the two hinges and 3) is that a SD roll cage? did you buy new?
Answers:

1 - I did - more info is at the beginning of the thread.
2 - it works ok - the door frame I built out of 1.5" square tubing and I would wager that part is as strong as any tire carrier. The hinges are the weak part at this point. Down the road I will use beefier hinges and box them into the outside cage tubing.
3 - P&P cage I bought off a member on the board
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  #327  
Old October 21st, 2015, 01:23 PM
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Real4X4
NAS 97 ST/NAS 93 110/62
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Quote:
Originally Posted by don View Post
Tub ready to go on the galvy frame.

Paint came out pretty good for a rattle job. Good coverage and looks way better than what was on there. I really like how the galvy cross pieces on the black tub look.

Attachment 132181

Nice job! Looks different the last time I visited.

------ Follow up post added October 21st, 2015 02:25 PM ------

Quote:
Originally Posted by don View Post
Lights all in - I still need to finish some wiring but waiting on a package with the connectors I need.

I am running twin reverse lights using clear UK/ROW Wilpac LED lights.

Attachment 132865
Like the patina with matching galvanized parts all over! Hoping will visit again once edelbrock set up is in.

Sal
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  #328  
Old October 21st, 2015, 07:35 PM
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Don Bunnell
'86 110 3dr ST
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Quote:
Originally Posted by budzny View Post
Nice job! Looks different the last time I visited. ------ Follow up post added October 21st, 2015 02:25 PM ------ Like the patina with matching galvanized parts all over! Hoping will visit again once edelbrock set up is in. Sal
Thanks Sal! Yeah - I am trying to keep the rugged body and paint but have everything else new. Kinda like an old pair of jeans and nice shirt and shoes.
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  #329  
Old October 21st, 2015, 07:39 PM
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Don Bunnell
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Almost all done putting the seatbox together. I probably posted before but the aluminum outer needed a bunch of fixes and then was brought over to GSD for Line-X.

The insides were rotted out in parts so I patched them up and got them galvanized.

Pretty stoked with how it looks. I just need to rivet the seat nut in once the paint dries on them.

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  #330  
Old October 21st, 2015, 07:39 PM
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Don Bunnell
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Another one:

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  #331  
Old October 21st, 2015, 08:16 PM
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William Skidmore
1994 D90
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This is all really looking good Don.
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There is nothing as permanent as a temporary fix. JSBriggs
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  #332  
Old October 21st, 2015, 09:20 PM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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Other than making me feel like a slacker, I'm loving the progress!
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  #333  
Old November 2nd, 2015, 03:25 PM
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Don Bunnell
'86 110 3dr ST
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Quote:
Originally Posted by airbornrover View Post
This is all really looking good Don.
Thanks Will!

------ Follow up post added November 2nd, 2015 04:25 PM ------

Quote:
Originally Posted by cgalpin View Post
Other than making me feel like a slacker, I'm loving the progress!
Haha thanks Charles!
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  #334  
Old November 2nd, 2015, 03:26 PM
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love that galvy, I love how this truck is coming together!

btw don - did you ever explain why you got rid of the toy axles? I seem to remember a long, long time ago (in a galaxy far far away) you had pretty much built up the axles and then you changed your mind.
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  #335  
Old November 2nd, 2015, 03:28 PM
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Don Bunnell
'86 110 3dr ST
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I've been messing with this seatbox install for the past week plus. Getting the galvy boxes to line up to a restored aluminum seatbox that was Line-X'd and then to a tub that had been redone has been a bear.

But... I am pretty happy with the results so far and think the Line-X top coat on a soft top seat box is the way to go.

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  #336  
Old November 2nd, 2015, 03:31 PM
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Don Bunnell
'86 110 3dr ST
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So after powder coating the original fuel filler I soon found that the replacing hose didn't work.

I didn't feel like spending more on parts but got a new Bearmach filler and now it fits well. For a gasket between the body and the filler I used some scrap Dynamat.

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  #337  
Old November 2nd, 2015, 03:35 PM
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Don Bunnell
'86 110 3dr ST
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With the P&P cage there are a couple of pieces that attach to the rear crossmember and then to the upper tub platform. With my 255 on the rear door I noticed all sorts of flex with the latch stop.

I made this little piece that will bolt to the lower cage supports. After install the rear door was a LOT stiffer. I will make a piece that will bolt to the as well as tie into the brackets for the rear most cage hoop.

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  #338  
Old November 2nd, 2015, 03:37 PM
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Don Bunnell
'86 110 3dr ST
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I know that last post was wordy - this might shed some light on what was built.

I still need to do the other side and that will stiffen up the upper hinge.

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  #339  
Old November 2nd, 2015, 03:39 PM
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1993 NAS 110
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I love your build...You're going to have an awesome truck! I'm normally not a linex fan for inside Defenders, but using it during a build where everything can still be easily dismantled makes it a great plus!!
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  #340  
Old November 2nd, 2015, 03:45 PM
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Don Bunnell
'86 110 3dr ST
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Quote:
Originally Posted by sonoronos View Post
love that galvy, I love how this truck is coming together! btw don - did you ever explain why you got rid of the toy axles? I seem to remember a long, long time ago (in a galaxy far far away) you had pretty much built up the axles and then you changed your mind.
I absolutely love galvy as well!

Over the course of working on this I have left galvy pieces outside and it just looks better. Very much like my cedar roof.

Still have the Toy axles! I am a huge fan of the rear with E-Locker. This will be the intro of the Toyo HiPinion front setup so have to see how that works. From my brief use of the rear on my 90 I think the Toy setup is very good. There isn't much to it and I bet axles could be made from a Toyota supplier. Would love to see someone bring the kit back.

Thanks for the props! Your work definitely motivates me :

------ Follow up post added November 2nd, 2015 04:49 PM ------

Quote:
Originally Posted by SonnyAK View Post
I love your build...You're going to have an awesome truck! I'm normally not a linex fan for inside Defenders, but using it during a build where everything can still be easily dismantled makes it a great plus!!
Thank you very much!

Yes - and look wise the lighter color fasteners/rivets against the black Line-X makes me smile every time with the contrast and exposed function.

I have had most every seatbox bolt in and out at least 3x each so dismantling it wouldn't take long!
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